Metal roof structure

ABSTRACT

Aluminum roof plates are affixed to the upper surfaces of roof boards on a building roof by the use of adhesive tape having adhesive material on both sides thereof which effects positive positioning of the plates on the roof boards and to form air layers between the roof boards and the aluminum plates. This arrangement acts to bring about desirable heat insulating and sound proofing effects. Preformed flange-shaped members are disposed at the connecting portions of the aluminum plates whereby adjacent ones of the aluminum plates may be joined to each other. Preformed metal members are also provided to form a roof ridge covering and eaves at the edges of the roof.

Unite States Patent [1 1 Mukoyama et a1.

1 1 METAL ROOF STRUCTURE [75] Inventors: Shigeki Mukoyama, Tokyo; Shigeru Obara, Yokohama, both of Japan [73] Assignee: Nippon Light Metal Company,

Tokyo, Japan [22] Filed: Oct. 12, 1972 [21] Appl. No.: 296,835

[56] References Cited UNITED STATES PATENTS 2,710,995 6/1955 Steker 52/11 X 2,990,650 7/1961 Attwood.... 3,053,716 9/1962 Finaw 52/302 X lzk 1, L5 l2.

[ Dec. 10, 1974 3,169,346 2/1965 Sklar 52/94 X 3,381,426 5/1968 Heidrich 52/57 X 3,401,493 9/1968 Lindner 52/622 X 3,408,786 11/1968 Snyker 52/420 X 3,436,881 4/1969 Schlecht 52/90 3,603,056 9/1971 Roth 52/461 X 3,732,659 5/1973 LaBarge 52/584 X FOREIGN PATENTS OR APPLICATIONS 715,247 8/1965 Canada 52/417 263,657 3/1965 Australia 52/461 Primary Examiner-Ernest R. Purser Assistant Examiner-Carl D. Friedman [5 7 ABSTRACT Aluminum roof plates are affixed to the upper surfaces of roof boards on a building roof by the use of adhesive tape having adhesive material on both sides thereof which effects positive positioning of the plates on the roof boards and to form air layers between the roof boards and the aluminum plates. This arrangement acts to bring about desirable heat insulating and sound proofing effects. Preformed flange-shaped members are disposed at the connecting portions of the aluminum plates whereby adjacent ones of the aluminum plates may be joined to each other. Preformed metal members are also provided to form a roof ridge covering and eaves at the edges of the roof.

2 Claims, 9 Drawing Figures METAL ROOF STRUCTURE The present invention relates to a building roof structure and more particularly to a building roof covering structure.

The invention is particularly applicable to a roof covering structure in which wide aluminum plates are used to cover a roof and will be described with particular reference thereto; however, it will be appreciated that the invention has broader applications and may be used in other instances where it is desired to provide a covering over a large, generally flat surface.

I-Ieretofore, conventional roof structures have been generally comprised of slate, clay tile, shingles and sheet metal which were conveniently affixed to the outside of a thin wood roof covering. In general, most of these prior roof structures are such that the individual roofing materials only cover a fairly small area and are necessarily overlapped with each other inorder to provide a roof with a weather-tight sea]. In these arrangements, there is always apprehension'that the roofing materials may be stripped off of the roof during foul weather to thus cause roof leakage. Furthermore, slating and clay tile particularly are of a relatively greater weight which is disadvantageous in that the basic roof structure must be made stronger in order to provide adequate support therefor. This, of course, adds undesirable expense to the roof structure.

One proposed structure for overcoming the above problem has been a roll-type structure. This structure is constructed in such a way that roof boards are laid Iaterallyacross rafters and the rolls fitted on the roof boards with an interval ranging from between 300mm to 450mm. Elongated metal plates having widths slightly greater than the interval of the rolls are employed wherein both sides of the metal plates are bent so as to rise and be fitted with second metal plates having widths slightly wider than the rolls. The second metal plates are overlappedon the rolls by means of tenor joints of convenient mechanical fasteners such as nails. Accordingly, the fabrication and application costs incurred at the construction site were considerable. Moreover, the metal plates were fixed to the rolls only at the side portions thereof which resulted in a condition termed as vertical floating of the metal plates, the generation of considerable noise during a strong wind, and undesirable physical characteristics as cracks and peeling. In addition, and as the metal plates are in direct contact with the roof boards, it caused considerable noise during periods of precipitation and insufficient heat insulation. Accordingly and to overcome these problems, there was required narrower intervals between the rolls employing a complicated connecting method. Furthermore, there is oftentimes a more complex structure adapted in which additional materials such as fiber board and the like are interposed between the roof boards and the metal plates.

This, of course, requires even more man hours and skill to complete the roof structure.

The present invention contemplates a new and improved roof structure which overcomes all of the above referred to problems and others and provides a metal roof contstruction which is simple, lightweight, inexpensive, easily installed and provides a reliable structure even during extremely heavy weather.

In accordance with the presentinvention, there is provided a metal roofing structure for covering at least a portion of an opening in a building. The structure includes in combination a roof board layer disposed so as to cover the opening. A plurality of adhesive strips are disposed at spacedintervals along the roof board and each includes a core portion having adhesive material exposed on at least two of the opposite sides thereof. One of the adhesive sides is disposed in adhesively gripping engagement with the roof layer with the other side exposed so as to be received in an adhesive gripping relationship with a metal roofing plate placed in a desired position over the roof layer. The cores of the adhesive strips act to maintain the roof board layer andthe roofing plate in a spaced apart relationship with an air layer therebetween.

In accordance with another aspect of the present invention, the metal roofing structure includes a performed metal member for connecting two roofing plates which are generally disposed in an edge to edge coplanar relationship. The metal member is designed to extend longitudinally along the top of and overlap the adjacent edges of the two roofing plates.

In accordance with another aspect of the present invention, the preformed metal member is'comprised of interfitting upper and lower portions designed to receive the adjacent edges of the two roof plates therebetween.

In accordance with still anotheraspect of the present invention, '21 performed structural member is provided for use with the roof structure in order to form eaves at the edges of the roof.

In accordance with yet another aspect of the present invention, a performed structural-member is provided to form a ridge area for the roof structure at the uppermost portion thereof when the structure is used to form a conventional inverted V-shaped roof.

The principal object of the present invention is the provision of a new metal roof structure which is simple and easy to install.

Another object of the present invention is the provision of a new metal roof structure which facilitates a speedy installation thereof.

Anothe object of the present invention is the provision ofa new metal roof structure which easily accommodates any effects imposed thereon by expansion and contraction of the component parts caused by environmental changes.

Still another object of the present invention is the provision of a new metal roof structure which provides for absorption of impact caused by natural elements impinging the metal roof plates.

- Still another objectof the present invention is the provision of a new metal roof structure which is readily adaptable to a use in a plurality of environments on different roof designs.

The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in this specification and illustrated in the accompanying drawings which forms a part hereof and wherein:

FIG. 1 is an enlarged cross-sectional view taken substantially along line IIII of FIG. 3;

FIG. 2 is a cross-sectional view taken substantially along line I-I of FIG. 1;

FIG. 3 is a perspective view showing structure of the subject invention;

the roofing FIG. 4 is a perspective view showing one formed metal member used for interconnecting adjacent metal roof plates;

FIG. 5 is a perspectlve view of another arrangement of the member used for joining adjacent edges of the metal roof plates;

FIG. 6 is a perspective view of yet another arrangement showing the formed metal member used for joining adjacent edges of the metal roof plates;

FIG. 7 is a perspective view of a roof ridge formed in accordance with the concepts of the subject invention;

FIG. 8 is a cross-sectional view of the structural elements used to form the roof eaves when using the concepts of the subject invention; and,

FIG. 9 is an elevational view of a roof eave formed in accordance with the concepts of the subject invention.

As best seen in FIGS. l3, the subject metal roofing structure is comprised of a roof board 1, roofing metal plate 2, adhesive tape 3 and metal member 4 formed as a roll.

Roof board 1, in turn, is comprised of an asbestos plate 5, a foaming styrol 6 and a particle board 7. It will be appreciated, however, that is is possible to separately use asbestos plate, particle board, wood plate, wood plywood or a hollow plywood by itself, or to select one or more of these materials and combine them with a foaming resin.

Roofing metal plate 2 may be constructed from a metal, but in the preferred embodiment of the invention, is constructed from an elongate aluminum plate whose width is generally in the range of 600-1200mm and whose thickness is generally in the range of 0.3-0.8mm.

Adhesive tape 3 most desirably is 10-50mm wide and its thickness is 2l0mm. The core of the tape is comprised ofa soft porous material and particularly a foaming resin of independent bubble such as, for example, foaming polyethylene, polyurethane, polychloroprene or butyl rubber although other materials could be satisfactorily used without departing from the scope and intent of the invention. An adhesive agent such as, for example, epoxy resin adhesive agent or acrylic resin adhesive agent is placed on both sides of the core. Elongated strips of the adhesive tape are adhesively disposed on the roof board I in slanting, vertical or longitudinal directions with an interval of from 100 to 300mm between successive strips. Roofing metal plates 2 are then placed over the roof board and held in position by the other side of the adhesive tape.

As a result, air layers 9 are formed between roof board 1, roofing metal plate 2. The air layer provides for heat and sound insulation in the structure. Further, expansion or contraction of the roof plate is absorbed by the air layer and adhesive strips which also prevent the corrugated deformation of the roof plate. Impact of forces such as, for example, precipitation is similarly absorbed by the cushion action of the tape. A groove shaped or a roll type formed aluminum member 4 is overlapped on the upper surfaces of the closely spaced edges of adjacent roofing metal plates 2. Member 4 may be formed by a conventional-forming process. A porous material 8 is conveniently packed inside formed member 4. As will be seen in FIG. 3 roof board 1 is directly mounted on the parallel spaced apart purlins 10. Since roof board 1 is manufactured to be thicker then conventional roof board, the conventional rafters are not required.

As best seen in FIGS. 46, there is shown therein an arrangement wherein aluminum formed member 4 is constructed of upper and lower portions or members which sandwich the roofing metal plates at the joined portion thereof. In this instance, a step like portion 11 is formed at the area of adjacent roof boards to be joined. The upper formed portion or member 4a is of a generally groove or channel shaped cross section and is provided with a flange 12a at each of the side walls thereof. Small projections 13 used for positioning purposes project into the channel from generally the center of the web of member 41. These projections are shown in the FIGURES as being spaced apart from each other along the web. The lower formed portion or member 4b also has a generally groove or channel like cross section. Two flanges 12b protrude from both sides of member 4b and a projection 14 is provided to facilitate connection with member 4a. Projection l4 protrudes into the channel area and includes a terminal portion 15 extending generally normal thereto which is to be connected to member 4a.

When in the mounted position, lower formed member 4b is fitted into a generally concave groove formed in roof board 1. After tape 3 and plates 2 have been desirably located, upper formed member 4a is positioned so that horizontal portion 15 of projection 14 is disposed between projections 13. The web of the upper formed member 4a and the horizontal portion 15 are then rigidly joined by means of screws 16 spaced longitudinally therealong. Other fasteners may also be employed which yield satisfactory connecting results. In the arrangement of FIG. 4, roof board I is comprised of a hollow thick plywood having excellent sound absorbing properties mounted with plate material 18 on I both upper and lower surfaces of spaced apart sash bars In the example of FIG. 5, two flanges 12b are disposed on each side of the lower formed member 4!) so that the inside ones of the flanges extend outwardly slightly higher or further than the outside ones of the flanges. Similarly, the inside ones of flanges 12a in member 4a project outwardly a lesser amount than do the outside ones of flanges 12a. In this arrangement, roofing metal plates 2 are thus connected in such a way that their end portions slightly rise obliquely aslant to obtain a flashing area. The side edges of the lower formed member 4b is projectedly formed with a projecting members 19 which extend normal to flanges 12b. Member 19 overlaps onto roof board 1 so that even if damage is caused to the joining portions of the roof boards, member 4b can still be mounted positively thereto. Projecting strip 14 in member 4b is shaped in a counter L-shaped style.

As shown in FIG. 6, the central portion of the web of the upper formed member 4a is shaped in chevron style to include an inwardly extending projection 20 for positioning purposes. Projection 20 abuts projection 14 when members 4a and 4b are in position to provide ease of location therefor. Also, projection 14 may be conveniently used as a guide to contact with the roofing metal plates 2 when they are located and secured to roof boards 1.

The structure contemplated for the roof ridge when using the subject invention is shown in FIG. 7. Roofing boards 1 are first fitted on the ridge piece 21, and roofing metal plates 2 sandwiched between lower formed member 4b and upper formed member 4a. A calking sheet 22 and a calking 23 are also provided at the ridge area. A cover 24 for the ridge is comprised of a ridge cover or proper generally chevron shaped to include hang down sides 25 formed downwardly from both end portions of the ridge cover or proper and mounting leg portions 26 extending outwardly from the sides in a generally parallel relationship to the proper. Lip members 27 are formed on the undersides of mounting leg portions 26 adjacent the outermost ends thereof and a packing material 28 is inserted into each of lip members 27. Cover 24 may also be formed from conventional forming processes. When the mounting is made, a space is formed between formed member 4a and the ridge cover proper so that the angle of the proper must be suitable bent to accommodate that angle. Rivets 29 are used to conveniently affix cover 24 to upper and lower formed members 4a and 417. Accordingly, the identical ridge cover may be used to meet any change in roof pitch.

In FIGS. 8 and 9, the arrangement contemplated for the eaves is shown. in this instance, the lower formed member 4b protrudes from roof board 1 and the upper formed member 4a protrudes even further from lower formed member 4b. A cover body generally designated 30 is disposed on the lower part of the projecting portions of upper and lower formed members 4a. and 4b. Body 30 includes a groove or channel shaped crosssectional portion 31 having a front wall 32, the upper end of which which becomes an inner gutter extended in a forward direction. The tip of the roofing metal plate is fitted on this extended portion and holes 33 are formed on the bottom surface of the groove portion for drainage purposes. The upper end of the rear wall 34 is in contact with the lower formed member 4b and extends in a generally downward direction. A flange 35 extends outwardly of wall 34 and a small groove portion 36 is formed on the rear part of the extended portion at the base of wall 34. A joining member of surface 37 is formed on the rear wall beneath groove portion 36 as it extends in its lowermost direction, which joining member is conveniently affixed to a verge-board 38 or another convenient area of the roof or building structures. The end of the eaves formed by upper formed member 4a receiving a cap 39 which covers the end faces of the formed members. Cover body 30 and cap 39 not only protect the structure from the elements but also provide the overall structure with a pleasing appearance.

It is to be understood that the specification of the roof construction herein disclosed and described are presented for the purpose of explanation and illustra tion only and are not intended to indicate the limits of the invention. It is my intention to include modifications and alterations of the invention insofar as they come within the scope of the appended claims or the equivalents thereof.

Having thus described our invention, we now claim:

1. A metal roofing structure for covering at least a portion of an opening in a building, said structure comprising in combination:

a roof board layer disposed so as to extend over said opening in a covering relationship therewith:

a plurality of adhesive strips disposed at spaced intervals along said layer, said strips each including a core portion having adhesive material exposed on at least two opposite sides thereof with one of said sides in adhesive gripping engagement with said layer;

a metal roofing plate received over said layer and retained in a desired position thereon by the adhesive material on the other of said sides, said cores of said adhesive strips maintaining said layer and said roofing plate in a desired spaced apart relationship from each other with an air layer therebetween;

a preformed metal member comprised of interfitting upper and lower portions for connecting two of said roofing plates disposed in a generally edge to edge coplanar relationship with each other, said upper and lower portions each including flanges, said preformed metal member lower portion having a pair of flanges disposed at each side thereof, the inside flange of each pair of flanges extending higher than its adjacent outside flange, and

said performed metal member upper portion extending longitudinally along the top of said two roofing plates and overlapping said edge thereof, said edges of said roofing plates being sandwiched be tween juxtaposed edges of opposed flanges of said upper and lower portions whereby the overlapped edges of said roofing plates are slightly raised.

2. The metal roofing structure as defined in claim 1 wherein said preformed metal member upper portion has a pair of flanges disposed at each side thereof, the inside flange of each pair of flanges extending a lesser distance than its adjacent outside flange. 

1. A metal roofing structure for covering at least a portion of an opening in a building, said structure comprising in combination: a roof board layer disposed so as to extend over said opening in a covering relationship therewith: a plurality of adhesive strips disposed at spaced intervals along said layer, said strips each including a core portion having adhesive material exposed on at least two opposite sides thereof with one of said sides in adhesive gripping engagement with said layer; a metal roofing plate received over said layer and retained in a desired position thereon by the adhesive material on the other of said sides, said cores of said adhesive strips maintaining said layer and said roofing plate in a desired spaced apart relationship from each other with an air layer therebetween; a preformed metal member comprised of interfitting upper and lower portions for connecting two of said roofing plates disposed in a generally edge to edge coplanar relationship with each other, said upper and lower portions each including flanges, said preformed metal member lower portion having a pair of flanges disposed at each side thereof, the inside flange of each pair of flanges extending higher than its adjacent outside flange, and said performed metal member upper portion extending longitudinally along the top of said two roofing plates and overlapping said edge thereof, said edges of said roofing plates being sandwiched between juxtaposed edges of opposed flanges of said upper and lower portions whereby the overlapped edges of said roofing plates are slightly raised.
 2. The metal roofing structure as defined in claim 1 wherein said preformed metal member upper Portion has a pair of flanges disposed at each side thereof, the inside flange of each pair of flanges extending a lesser distance than its adjacent outside flange. 